Method for joining vehicle frame components

Abstract

A method of joining two vehicle frame components made from dissimilar materials includes providing a first frame component, and providing a second frame component made from a material which is dissimilar to the material used to make the first frame component, where one of the first and second frame components is a metallic component made of a metallic material. A portion of one of the first and second frame components is positioned within a portion of the other of the frame components in an overlapping manner, thereby forming an overlapping portion. A metallic band is disposed around the overlapping portion, and an inductor is positioned around the metallic band. The inductor is energized to generate a magnetic field for collapsing the band about the overlapping portion at a velocity sufficient to magnetic pulse weld the band and metallic component to each other, thereby securing the first and second frame components together.

What is claimed is: 
     
       1. A method of joining two vehicle frame components made from dissimilar materials, the method comprising the steps of: a. providing a first frame component;   b. providing a second frame component made from a material that is dissimilar to a material used to make the first frame component, wherein at least one of the first and second frame components is made from a metallic material;   c. positioning a portion of the first frame component within a portion of the second frame component in an overlapping manner, thereby forming an overlapping portion;   d. disposing a metallic band around the overlapping portion;   e. providing an inductor around the metallic band; and   f. energizing the inductor to generate a magnetic field for collapsing the metallic band about the overlapping portion and magnetic pulse welding the metallic band to the metallic component, thereby securing the first and second frame components together.   
     
     
       2. The method of claim 1 in which both the first and second components are metallic components. 
     
     
       3. The method of claim 1 in which the first component is a side rail and the second component is a cross member. 
     
     
       4. The method of claim 3 in which the side rail is made of a metallic material and the cross member is made of a composite material. 
     
     
       5. The method of claim 4 in which a portion of the side rail is positioned within a portion of the cross member to form the overlapping portion. 
     
     
       6. The method of claim 3 in which a portion of the side rail is positioned within a portion of the cross member to form the overlapping portion. 
     
     
       7. The method of claim 1 in which the first component is a side rail and the second component is a cross member, where a portion of the cross member is positioned within a portion of the side rail to form the overlapping portion. 
     
     
       8. The method of claim 1 in which an insert is positioned within the metallic component to provide support for the metallic component during the step of welding the band and the metallic component to each other. 
     
     
       9. A method of joining two vehicle frame components made from dissimilar materials, the method comprising the steps of: a. providing a first frame component made from a metallic material;   b. providing a second frame component made from a composite material, the second frame component having a protrusion;   c. positioning a portion of the first frame component within a portion of the second frame component in an overlapping manner, thereby forming an overlapping portion, wherein the protrusion is within the overlapping portion;   d. disposing a metallic band around the overlapping portion;   e. providing an inductor around the metallic band; and   f. energizing the inductor to generate a magnetic field for collapsing the metallic band about the overlapping portion and magnetic pulse welding the metallic band to the metallic component, thereby securing the first and second frame components together, wherein the metallic band is crimped over the protrusion.   
     
     
       10. The method of claim 9 in which the protrusion is a peripheral rim on the second frame component. 
     
     
       11. The method of claim 9 in which the second component has a circular cross-section, and the protrusion is annular. 
     
     
       12. The method of claim 11 in which the first component is a side rail and the second component is a cross member. 
     
     
       13. The method of claim 9 in which the protrusion is integrally molded with the second frame component. 
     
     
       14. The method of claim 13 in which the protrusion has a thickness within the range of from about 70 percent to about 150 percent of the thickness of the second frame component. 
     
     
       15. A method of joining two vehicle frame components made from dissimilar materials, the method comprising the steps of: a. providing a metallic side rail;   b. providing a cross member made from a composite material, the cross member having a protrusion;   c. positioning a portion of the side rail within a portion of the cross member in an overlapping manner, thereby forming an overlapping portion, wherein the protrusion is within the overlapping portion;   d. disposing a metallic band around the overlapping portion;   e. providing an inductor around the metallic band; and   f. energizing the inductor to generate a magnetic field for collapsing the metallic band about the overlapping portion and magnetic pulse welding the metallic band to the side rail, thereby securing the side rail and the cross member together, wherein the metallic band is crimped over the protrusion.   
     
     
       16. The method of claim 15 in which the protrusion has a thickness within the range of from about 70 percent to about 150 percent of the thickness of the second frame component. 
     
     
       17. The method of claim 15 in which the protrusion is an annular peripheral rim on the cross member, and the cross member has a circular cross-section. 
     
     
       18. The method of claim 17 in which the protrusion is integrally molded with the second frame component. 
     
     
       19. The method of claim 18 in which the protrusion has a thickness within the range of from about 70 percent to about 150 percent of the thickness of the second frame component. 
     
     
       20. The method of claim 19 in which an insert is positioned within the metallic component to provide support for the metallic component during the step of welding the band and the side rail to each other.